Method of molding material and molded products

Abstract

METHOD FOR MOLDING MATERIAL AND MOLDED PRODUCTS. The present invention relates to a method for molding material with a plurality of interstices (such as a network of voids) and molded products formed by the method. In preferred embodiments, the material is a foam such as a polyurethane foam. The molding method allows such materials to be molded using contour molding machining methods, including computer numerical control (CNC) milling, which is provided only by way of example. To be contrasted with methods of manufacturing a molded material (such as by polymerization of a solution or emulsion of monomers), in several respects the present invention contemplates the molding of existing (pre-formed) materials with a plurality of interstices, such as a network of voids.

Description

1 / 52 “METHOD OF MOLDING MATERIAL AND MOLDED PRODUCTS” FIELD OF THE INVENTION

[0001] The present invention relates to a method of molding material with a plurality of interstices (such as a network of voids) and molded products formed by the method. In preferred embodiments, the material is a foam such as a polyurethane foam. The molding method allows such materials to be molded using contour molding machining methods, including computer numerical control (CNC) milling, which is provided only by way of example. To be contrasted with methods of manufacturing a molded material (such as by polymerization of a solution or emulsion of monomers), in several respects the present invention contemplates the molding of existing (preformed) materials with a plurality of interstices, such as a network of voids. BACKGROUND OF THE INVENTION

[0002] Flexible foam manufacturing is the means by which foams are molded to a desired end result by molding foam stock or casting resin systems (excluding casting for mass-produced foam stock intended for manufacturing). Molding methods include: hand molding; and computer numerically controlled molding, examples being CNC milling machines, lathes, lathe-mills, and multi-axis robotic arm molding.

[0003] Materials such as polyurethane foam are notoriously difficult to mold precisely. While it is relatively easy to cut these foams with blades, saws, and the like, attempting to contour these foams using conventional machining methods (such as computer numerical control (CNC) methods) leads to imprecise contours and generally undesirable machining finishes. In particular, the present inventor believes that the inferior finish is caused by the deformation of the foam by the machining tool during the molding process, leading Petition 870220091681, dated 06 / 10 / 2022, pp. 107 / 177 2 / 52 due to cutting, or even tearing, the material in an imprecise location. Instead of generating a smooth surface, this machining creates a rough surface.

[0004] Despite this challenge, molded polyurethane foam is widely used in seat filling, packaging, etc. Often, the user desires a precisely molded polyurethane product for applications such as wheelchair seats, where a custom-molded product is desired.

[0005] There have been very few attempts to overcome the problems described in this document. In general, the methods that have been employed previously can be categorized as:

[0006] · Cryogenic processes. This machining method is relatively fast, accurate and achieves desirable results at the cost of higher equipment costs (which must be able to withstand extreme temperatures), handling, storage and excessive use of liquefied gaseous refrigerants along with exposure to fine foam dust and liquefied gas hazards;

[0007] · Liquid freezing. This method involves saturating the foam with water before freezing the water in situ. Freezing is a simplified version of the cryogenic process that allows for lower costs comparable to cryogenic and dry machining, allowing a sufficiently low temperature to be maintained using frozen water. However, this process requires the water to remain frozen (this can be aided by cooling the foam and water) throughout all stages of the molding process to achieve optimal results. The expansion of the water as it solidifies results in microfracture of the foam.Furthermore, freezing water actually leads to less than ideal machining quality and precision, as machining tolerances can be unpredictably disrupted by the expansion of water within the reduced-temperature foam, along with the loss of molten ice around the molding surface when a high-speed / friction machining tool comes into play. Petition 870220091681, dated 06 / 10 / 2022, pp. 108 / 177 3 / 52 in contact with the surface. Another problem with this method is that the water needs to be contained and the machine components must be water-compatible to prevent corrosion, electrical failures, and spillage; and

[0008] · Dry machining. This method refers to techniques other than cryogenic and liquid freezing described above and requires extended machining times, state-of-the-art equipment and tools, and exposes technicians to hazardous dust, providing only limited geometry.

[0009] Due to the limitations of these methods, including the significant health risk of generating fine particles, traditional manual molding methods continue to be widely used in foam manufacturing.

[0010] In addition to molding flexible foam, it is often desired to mold porous metallic materials that are typically inflexible. These materials suffer from different problems compared to flexible foams. For example, machining porous metallic materials produces burrs that vary in size and shape depending, in part, on the temperature and the material used. At high temperatures, the cutting tool and the point of contact with the metal become softer, leading to a tendency for the metals to plastically shift to form fouling or burrs. Such temperatures also accelerate the dulling of machining tools. To overcome these problems, a coolant can be applied to reduce the material temperature, hardening the metal to produce cleaner cuts and avoid burrs, fouling, and associated damage.Other teachings in the area of ​​machining porous metals clarify the problem as a result of ductile shear, and the solution for fouling depends mainly on obtaining "brittle shear" using cryogenic methods.

[0011] As with all machining methods, in the methods mentioned above it is necessary to ensure that the material to be shaped is securely retained during the process of Petition 870220091681, dated 06 / 10 / 2022, pp. 109 / 177 4 / 52 molding. Traditionally, the material is stapled or otherwise fixed, for example, by using an adhesive such as cyanoacrylate or similar "super glue" adhesives. Such techniques typically damage the material due to the direct mechanical action of the staples or as a result of the excessive force required to break the bond with the adhesive.

[0012] It is an object of the present invention to address one or more of the foregoing problems or at least to provide the knowledgeable recipient with a useful choice. SUMMARY OF THE INVENTION

[0013] In a first aspect, the invention provides a method for molding an elastic or viscoelastic material with a plurality of interstices, the method including the steps of:

[0014] i. provide an elastic or viscoelastic material with a plurality of interstices;

[0015] ii. bring the material into contact with an additive in such a way that at least a portion of the additive is incorporated within at least a portion of the plurality of interstices of the material;

[0016] iii. subject the material to conditions such that at least a portion of the incorporated additive solidifies, hardens and / or stiffens;

[0017] iv. molding the material incorporating the solid, hard and / or rigid additive in order to form a molded material incorporating the additive; and

[0018] v. remove at least a portion of the incorporated additive from the molded material incorporating the additive,

[0019] where the additive solidifies, hardens and / or stiffens at a temperature above 0 °C.

[0020] In some embodiments, the elastic or viscoelastic material with a plurality of interstices is an elastic or viscoelastic material with a network of voids. Petition 870220091681, dated 06 / 10 / 2022, pp. 110 / 177 5 / 52

[0021] Consequently, in a second aspect, the invention provides a method for molding an elastic or viscoelastic material with a network of voids, the method including the steps of:

[0022] i. provide an elastic or viscoelastic material with a network of voids;

[0023] ii. bring the material into contact with an additive so that at least a portion of the additive is incorporated within at least a portion of the material's void network;

[0024] iii. subject the material to conditions such that at least a portion of the incorporated additive solidifies, hardens and / or stiffens;

[0025] iv. molding the material incorporating the solid, hard and / or rigid additive in order to form a molded material incorporating the additive; and

[0026] v. remove at least a portion of the incorporated additive from the molded material incorporating the additive,

[0027] where the additive solidifies, hardens and / or stiffens at a temperature above 0 °C.

[0028] The method of the present invention allows the production of a molded elastic or viscoelastic material with a desirable surface finish. The method utilizes an additive that solidifies, hardens, and / or stiffens at a temperature above the freezing point of water (0 °C at standard atmospheric pressure, 101,325 kPa). The additive is incorporated within the material so that the material can be molded while the additive is solidifying, hardening, and / or stiffening, thus preventing undesirable deformation of the material as it is molded.

[0029] By way of example only, in some embodiments, the additive is a wax and the elastic or viscoelastic material with a plurality of interstices (like a network of voids) is a polyurethane foam. In these embodiments, the method may involve the incorporation of Petition 870220091681, dated 06 / 10 / 2022, pp. 111 / 177 6 / 52 Melted wax is placed inside the material which, after cooling to room temperature, solidifies and the foam can then be molded by CNC milling. At least some of the wax is then removed from the molded foam.

[0030] Without wanting to be limited by theory, it is believed that the present methods allow the material to be molded without substantially altering the elastic modulus of the material itself. Furthermore, an additive can be selected so that the temperature difference between the additive being liquid and solid can be limited so that the material's shrinkage, if any, is very limited. Additionally, by carefully modulating the amount of additive incorporated into the material, it is possible to avoid saturation of the material, thus providing greater control over potential expansion or contraction.

[0031] It is further believed that, while previously published cryogenic approaches weaken and impair the structure of the foam material at a molecular level to achieve machinability, the present invention creates a mechanical advantage to the benefit of the machining tool by concentrating a shear force between the high inertia of the immobilizing additive (particularly wax) relative to the high moment of the rotating cutting edge of the tool.

[0032] As such, the present invention represents a significant advance over previously published methods, as it allows the molding of elastic or viscoelastic materials at room temperature and a range of other temperatures above the freezing point of water. The advantages of the present invention are comprised of the self-healing characteristics of the additive used in some embodiments – for example, any additive (such as wax) that is temporarily melted by the machining tool subsequently hardens after the tool passes, thus again contributing to the rigidity of the material. The use of a wax-based additive can also lubricate the machine and cutting tool to increase tool life and can do so while reducing the Petition 870220091681, dated 06 / 10 / 2022, pp. 112 / 177 7 / 52 risk of electrical failure otherwise possible when using water in the liquid freezing methods previously published.

[0033] In a third aspect, the invention provides an elastic or viscoelastic material molded with a plurality of interstices (like a network of voids) prepared by the method of the first or second aspects.

[0034] In a fourth aspect, the invention provides the use of an additive that is solid, hard and / or rigid at a temperature above 0 °C to mold an elastic or viscoelastic material with a plurality of interstices (like a network of voids) within which the additive has been incorporated.

[0035] In a fifth aspect, the invention provides an elastic or viscoelastic material contoured with a plurality of interstices (like a network of voids), wherein at least a portion of the material has an additive incorporated into the material, wherein the additive is solid, hard and / or rigid at a temperature above 0 °C.

[0036] As used in this document, the term “contoured” refers to the shape of an article that has been subjected to contouring, contour machining, 3D machining, or 3D contour machining techniques.

[0037] In a sixth aspect, the invention provides a method for molding an elastic or viscoelastic material with a plurality of interstices, the method including the steps of:

[0038] i. provide an elastic or viscoelastic material with a plurality of interstices;

[0039] ii. bring the material into contact with an additive in such a way that at least a portion of the additive is incorporated within at least a portion of the plurality of interstices of the material;

[0040] iii. subject the material to conditions such that at least a portion of the incorporated additive solidifies, hardens and / or stiffens;

[0041] iv. molding the material incorporating the additive Petition 870220091681, dated 06 / 10 / 2022, pp. 113 / 177 8 / 52 solid, hard and / or rigid so as to form a molded material incorporating the additive; and

[0042] v. remove at least a portion of the incorporated additive from the molded material incorporating the additive,

[0043] wherein the additive is not water and the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions among: thermal, magnetic, electrical, chemical and / or electromagnetic.

[0044] In a seventh aspect, the invention provides a method for molding an elastic or viscoelastic material with a network of voids, the method including the steps of:

[0045] i. provide an elastic or viscoelastic material with a network of voids;

[0046] ii. bring the material into contact with an additive so that at least a portion of the additive is incorporated within at least a portion of the material's void network;

[0047] iii. subject the material to conditions such that at least a portion of the incorporated additive solidifies, hardens and / or stiffens;

[0048] iv. molding the material incorporating the solid, hard and / or rigid additive in order to form a molded material incorporating the additive; and

[0049] v. remove at least a portion of the incorporated additive from the molded material incorporating the additive,

[0050] wherein the additive is not water and the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions among: thermal, magnetic, electrical, chemical and / or electromagnetic.

[0051] In some embodiments, the elastic or viscoelastic material with a plurality of interstices is an elastic or Petition 870220091681, dated 06 / 10 / 2022, pp. 114 / 177 9 / 52 viscoelastic with a network of voids.

[0052] In an eighth aspect, the invention provides a method for molding an elastic or viscoelastic material with a network of voids, the method including the steps of:

[0053] i. provide an elastic or viscoelastic material with a network of voids;

[0054] ii. bring the material into contact with an additive so that at least a portion of the additive is incorporated within at least a portion of the material's void network;

[0055] iii. subject the material to conditions such that at least a portion of the incorporated additive solidifies, hardens and / or stiffens;

[0056] iv. molding the material incorporating the solid, hard and / or rigid additive in order to form a molded material incorporating the additive; and

[0057] v. remove at least a portion of the incorporated additive from the molded material incorporating the additive,

[0058] where the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions among: magnetic, electrical, chemical and / or electromagnetic.

[0059] In a ninth aspect, the invention provides an elastic or viscoelastic material molded with a plurality of interstices (like a network of voids) prepared by the method of the fifth aspect or the sixth aspect.

[0060] In a tenth aspect, the invention provides the use of an additive to shape an elastic or viscoelastic material with a plurality of interstices (like a network of voids) within which the additive has been incorporated, wherein the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions from among: magnetic, electrical, chemical and / or electromagnetic. Petition 870220091681, dated 06 / 10 / 2022, pp. 115 / 177 10 / 52

[0061] In an eleventh aspect, the invention provides an elastic or viscoelastic material contoured with a plurality of interstices (like a network of voids), wherein at least a portion of the material has an additive incorporated into the material, wherein the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions from among: magnetic, electrical, chemical and / or electromagnetic.

[0062] In a twelfth aspect, the invention provides a method for forming a molded elastic or viscoelastic material with a plurality of interstices, the method including the steps of:

[0063] i. in a container, place an additive in contact with a resin capable of being cured to form an elastic or viscoelastic material to form a mixture;

[0064] ii. degas the mixture, such as by vacuum, and / or mix the mixture to form a homogeneous mixture;

[0065] iii. cure the resin in order to form an elastic or viscoelastic material incorporating at least part of the additive;

[0066] iv. molding the material incorporating the additive in order to form a molded material incorporating the additive; and

[0067] v. optionally remove at least a portion of the incorporated additive from the molded material that incorporates the additive,

[0068] wherein the additive is not water and the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions among: thermal, magnetic, electrical, chemical and / or electromagnetic.

[0069] In a thirteenth aspect, the invention provides a method for forming a molded elastic or viscoelastic material with a network of voids, the method including the steps of:

[0070] i. in a container, place an additive in contact with a resin capable of being cured to form an elastic or viscoelastic material to form a mixture; Petition 870220091681, dated 06 / 10 / 2022, pp. 116 / 177 11 / 52

[0071] ii. degas the mixture, such as by vacuum, and / or mix the mixture to form a homogeneous mixture;

[0072] iii. cure the resin in order to form an elastic or viscoelastic material incorporating at least part of the additive;

[0073] iv. molding the material incorporating the additive in order to form a molded material incorporating the additive; and

[0074] v. optionally remove at least a portion of the incorporated additive from the molded material that incorporates the additive,

[0075] wherein the additive is not water and the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions among: thermal, magnetic, electrical, chemical and / or electromagnetic.

[0076] Other aspects of the invention, which should be considered in all their innovative aspects, will become apparent to those skilled in the art after reading the following description which provides at least one example of a practical application of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0077] One or more embodiments of the invention will be described below by way of example only, and without being intended to be limiting, with reference to the following drawings, in which:

[0078] Figure 1 shows a schematic flowchart for the process of incorporating a wax additive into a foam material and attaching that material to a machining surface;

[0079] Figure 2 shows a schematic flowchart for the machining process of one or two sides of a foam material incorporating wax;

[0080] Figure 3 shows a schematic flowchart for the process of removing at least a portion of the incorporated wax additive from a foam material;

[0081] Figure 4 shows a schematic flowchart. Petition 870220091681, dated 06 / 10 / 2022, pp. 117 / 177 12 / 52 for the methods of the invention being applied to a multitude of molded stocks;

[0082] Figure 5 shows a schematic flowchart for a method of the invention in which a solid additive is used to generate a molded article;

[0083] Figure 6 shows a schematic flowchart for multiple embodiments of the invention method, including the step of contacting a foam with an additive;

[0084] Figure 7 shows a schematic flowchart for using a container as a model;

[0085] Figure 8 shows a schematic flowchart for a process using solid granules, powders, etc. and other additives. Optionally, these can be manipulated by external stimuli - whether solid or not;

[0086] Figure 9 shows a schematic flowchart for a process in which the addition or removal of heat can be used to modify the properties of the additive;

[0087] Figure 10 shows a schematic flowchart for a continuation process of that shown in Figure 9;

[0088] Figure 11 shows a schematic flowchart for an additive removal process.

[0089] Figures 12 and 13 show a schematic flowchart for a process in which a model is used to create an impression on a foam before CNC machining.

[0090] The figures do not necessarily represent the order of operation or any association between the steps on the page.

[0091] Foam is used as an example for illustrative purposes only.

[0092] A vacuum bag is intended for demonstration purposes only, for example. A vacuum bag can be arranged in other Petition 870220091681, dated 06 / 10 / 2022, pp. 118 / 177 13 / 52 suitable arrangements, such as sealing a suitable sheet to a solid plate or as a flexible reinforcement affixed between two solid plates to allow the sheets to join together when under vacuum. The plates may have one or more inlets / outlets as distinct openings or valves; or a plurality of openings or valves that may converge by means of a manifold.

[0093] A press can be mechanical or manual; or operated by hand; or a combination of an arrangement of bags as described above that is compressed mechanically or manually. DETAILED DESCRIPTION OF THE INVENTION

[0094] As used in this document, the term “elastic or viscoelastic” material refers to a class of materials that is:

[0095] i. resilient deformable (elastic); or

[0096] ii. substantially resilient deformable, so that some energy is dissipated through the deformation process from a first position to a second position and returning substantially to the first position (viscoelastic).

[0097] The material of the invention includes a matrix of solid material within which there is a plurality of interstices, like a network of voids. Examples of interstices are: cells with incomplete wall region(s); tunnels; channels; orifices; empty platelets; interstitial spaces; etc. The interstices may be in fluid communication so that an additive can penetrate the material, such as through a network of voids. The interstices may be arranged in a set of interstices, as in a honeycomb material. Such interstices may or may not be in fluid communication with one or more other interstices. However, such interstices are capable of having additives added to and / or removed from them. Preferably, such interstices will be capable of having additives added to and removed from them.

[0098] As such, the materials of the invention must be distinguished from materials that: Petition 870220091681, dated 06 / 10 / 2022, pp. 119 / 177 14 / 52

[0099] · are not capable of having additives added to them and / or

[0100] · are not able to have additive removed from them and / or [0101 ] · do not contain a network of voids that are in fluidic communication and normally contain a significant number of discrete gas cells.

[0102] By way of example only, open-cell foam is an elastic or viscoelastic material with a network of voids and is capable of being used in the methods of the invention, whereas closed-cell foam is not an elastic or viscoelastic material with a network of voids capable of being used in the methods of the invention.

[0103] As used in this document, “interstice” refers to a space within the material that can, for example, be filled with gas, liquid, or some other material that is not elastic or viscoelastic. Interstices are generally small spaces, but still capable of, for example, being filled with gas, liquid, or some other material that is not elastic or viscoelastic. Interstices can be regularly shaped or irregularly shaped. Interstices can be the same size or different sizes. For example, in a foam, interstices generally consist of a variety of spaces of different sizes. The size of any interstice can be measured in various ways, including minimum, maximum, or average linear dimension. It may be convenient to measure the size of the interstice(s) by the average linear dimension in 2 or more geometric axes, such as 2 orthogonal geometric axes.The lower size limit will typically be limited only by the ability of a gas, liquid, or some other non-elastic or viscoelastic material to penetrate at least a portion of the interstitium(s). The upper size limit will typically be unlimited, although the interstices have average linear dimensions on the order of up to about 1,000. Petition 870220091681, dated 06 / 10 / 2022, pp. 120 / 177 15 / 52 mm, as well as up to about 500 mm, as well as up to about 300 mm, as well as up to about 100 mm, as well as up to about 50 mm, as well as up to about 25 mm, as well as up to about 10 mm, as well as up to about 5 mm, as well as up to about 2 mm, as well as up to about 1 mm will be preferred. In some embodiments, the interstices will be on the order of at least 0.001 mm in size, as well as at least 0.01 mm in size, as well as at least 0.1 mm in size. It will be understood that various techniques can be used to form materials with a plurality of interstices, such as emulsion polymerization of a polyurethane. Such techniques will generally produce a material with interstices with a size distribution.Therefore, in some embodiments, the dimension limits described in this document will be applied to at least 60% of the interstices, such as at least 70% of the interstices, such as at least 80% of the interstices, such as at least 90% of the interstices, such as at least 95% of the interstices. In some embodiments, the dimension limits described in this document will be applied to 100% of the interstices.

[0104] As used in this document, plurality means two or more. It will generally be the case that the elastic or viscoelastic material has not only a plurality of interstices, but at least several (3) interstices, such as an infinity of interstices. The elastic or viscoelastic material may have at least 5, such as at least 10, such as at least 20, such as at least 50, such as at least 100, such as at least 500, such as at least 1,000, interstices.

[0105] As used in this document, “void” refers to a space within the material that can, for example, be filled with gas, liquid, or some other material that is not elastic or viscoelastic. Voids are generally small spaces, but still capable of, for example, being filled with gas, liquid, or some other material that is not elastic or viscoelastic. Voids can be regularly shaped or irregularly shaped. Voids can be the same size or different sizes. For example, in a foam, the Petition 870220091681, dated 06 / 10 / 2022, pp. 121 / 177 16 / 52 Voids generally consist of a variety of spaces of different sizes. The size of any given void can be measured in several ways, including minimum, maximum, or average linear dimension. It may be convenient to measure the size of the void(s) by the average linear dimension along 2 or more geometric axes, such as 2 orthogonal geometric axes. The lower size limit will typically be limited only by the ability of a gas, liquid, or some other non-elastic or viscoelastic material to penetrate at least a portion of the void(s). The maximum size limit will typically be unlimited, although voids with average linear dimensions on the order of up to about 1,000 mm, such as up to about 500 mm, such as up to about 300 mm, such as up to about 100 mm, such as up to about 50 mm, such as up to about 25 mm, such as up to about 10 mm, such as up to about 5 mm, such as up to about 2 mm, such as up to about 1 mm will be preferred.In some embodiments, the interstices will be on the order of at least 0.001 mm in size, such as at least 0.01 mm in size, such as at least 0.1 mm in size. It will be understood that various techniques can be used to form materials with a network of voids, such as emulsion polymerization of a polyurethane. Such techniques will generally produce a material with voids with a size distribution. As such, in some embodiments, the dimension limits described in this document will apply to at least 60% of the voids, such as at least 70% of the voids, such as at least 80% of the voids, such as at least 90% of the voids, such as at least 95% of the voids. In some embodiments, the dimension limits described in this document will apply to 100% of the voids.

[0106] It will be understood that not all voids in the material of the invention are necessarily in fluid communication with each other. It is sufficient for the present invention that a significant number (such as at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%) Petition 870220091681, dated 06 / 10 / 2022, pp. 122 / 177 17 / 52 are in fluidic communication with each other. As such, the term “network of voids,” as used in this document, refers to a significant number (such as at least 10%) of the voids that are in fluidic communication with each other. Typically, at least 50% (such as at least 60%, at least 70%, at least 80%, at least 90%) of the voids are in fluidic communication with each other.

[0107] An example of a material with a plurality of interstices, wherein each of the interstices are not necessarily interconnected cells, but are functionally the same as the more extensively described lattice voids immediately above, is a flexible elongated honeycomb material that is open-celled, but in which an additive would not easily (or at all) pass from cell to cell. This is a common material and can be used as a substitute for regular flexible polyurethane foams. Another example might be gill-like or resemble a soft flexible heat sink, so that it includes a multitude of elongated members (such as plates, vanes, or rods). In such an example, the material may have voids (between the elongated members), but without substantial interconnection between the voids.

[0108] Other such materials of the invention with a plurality of interstices may be described as having a brush-like appearance, wherein the material has parallel or linear filaments (and may be fixed at one end or at both ends). For example, a material with the appearance of a dense silicone brush may be molded using the disclosed invention. The aim of this may be to prototype or produce a small production run of contoured brushes, or various vibration damping and weakening systems.

[0109] It will be understood that the present invention is based, in part, on the ability of the additive to penetrate the material through interstices, such as voids. As such, the interstices (such as voids) are limited in size and other properties (including the properties Petition 870220091681, dated 06 / 10 / 2022, pp. 123 / 177 18 / 52 chemical and / or physical properties of the surrounding matrix of the material) only by the requirement that the additive can penetrate the material through interstices, such as voids, to a sufficient degree to allow the method of the invention to be carried out.

[0110] Materials with a plurality of interstices (such as a network of voids) can be formed in various ways, including in some embodiments by incorporating an inflating agent, such as sodium bicarbonate, into a material so that the agent releases a gas when the material is subjected to certain conditions, such as heating. Examples of such materials with a plurality of interstices (such as a network of voids) include foams, felts, trusses, scaffolding, rolled materials, meshes, and webs. Preferably, the material of the present invention is a foam, and it is convenient (for illustrative purposes only) to describe the invention with respect to foams, although it is understood that the general principle described herein can be applied to all elastic or viscoelastic materials with a plurality of interstices (such as a network of voids).Foams can be formed at least partially, if not completely, from a polymer that is either natural or synthetic.

[0111] It will be understood that there are many known materials with a plurality of interstices (such as a network of voids) that are neither elastic nor viscoelastic. These materials include: ceramic foams; metallic foams; rigid foams (e.g., expanded polystyrene (EPS) and extruded polystyrene (XPS)); and rigid grades of foams (e.g., rigid polyurethane (PU), rigid melamine foam). Such materials are not contemplated by the present invention, for the reasons discussed below, including that the methods of the present invention can advantageously use the elastic or viscoelastic properties of the material to incorporate the additive. Without these properties, incorporation of the additive, and subsequent removal, is more difficult to achieve.

[0112] It will be appreciated that the material should be Petition 870220091681, dated 06 / 10 / 2022, pp. 124 / 177 19 / 52 preferably selected to be substantially resistant to the physical and / or chemical conditions to which it is subjected in the method of the invention.

[0113] As used in this document, the term “additive” refers to a component that is distinct from the elastic or viscoelastic material and that can be incorporated within at least a portion of the plurality of interstices (such as a network of voids) of the material. Examples of additives include:

[0114] · wax or wax-like compounds and mixtures thereof. The wax may preferably be insoluble in water. The wax-like compound may be water-soluble such as PEGs, panthenol, wax-like emulsifiers and mixtures thereof;

[0115] • crystalline solid / supersaturated liquid (e.g., a supersaturated solution that is stable at room temperature (e.g., sodium acetate trihydrate or similar); a supersaturated solution that is not stable at room temperature but requires less heat to remain liquid than, for example, pure molten sucrose; crystalline materials in a molten state (such as sucrose) that crystallize upon cooling (this example may also include one or more modifiers to lower the melting point)). Sugar salts and alcohols may be used. Eutectics of sugar alcohols and other mixtures are also useful;

[0116] • liquid crystallization compounds (e.g., electrically active liquid that would self-assemble to form a more rigid material and provide some strength, such as an electrically active material consisting of a solution containing an amphiphilic mesogen that could gel or harden in response to an electrical stimulus and may be reversible if it is not water-soluble for removal);

[0117] • non-Newtonian compounds that solidify, including those that solidify against machining (e.g., corn starch and water that harden in response to applied shear forces - these examples Petition 870220091681, dated 06 / 10 / 2022, pp. 125 / 177 20 / 52 can also benefit from applied sonic vibrations; corn starch and oil as an electrorheological liquid that hardens upon application of an electrical stimulus). The advantages are the control of airborne particles and the apparent self-regenerating nature of some of these materials that can flow into previously cut interstices (such as voids);

[0118] · granules / powders / other solids (e.g., ferrous powders or granules (e.g., iron powder) that can flow into some materials with a plurality of interstices (like a network of voids) and then form a quasi-solid upon application of a magnetic stimulus (friction between the granules and the foam will essentially lock it in place). Such powders / granules can be removed by gravity and / or sonic agitation, optionally in combination with magnetic forces and / or in a liquid to enhance this). In general, an advantage of powders or granules with the use of magnets is the ease with which the powders or granules can be separated from the residual material;

[0119] • granules / powders / other solids that can flow in some materials with a plurality of interstices (like a network of voids) without any magnetic influence or other change of condition. For example, a foam can be fixed in a container with walls; an additive powder is agitated in the plurality of interstices (like a network of voids) of the foam, as well as any spaces between the foam and the walls of the container; the foam with powder additive is thus placed in a packed and supported condition so that the foam and the additive can be molded; before the molded foam is agitated (such as after removal from the container) to remove the powder additive.The nominal advantages of using granules / powders / other solids that can flow into some materials with a plurality of interstices (such as a network of voids) are: a possible reduction in energy requirements without the need for substantial heating, as the powder can be vibrated in and vibrated out or melted out if necessary; faster processing time, as the additive does not require cooling; and little. Petition 870220091681, dated 06 / 10 / 2022, pp. 126 / 177 21 / 52 or no change in the size of the filled foam and the empty foam, as there is no thermal expansion;

[0120] · granules / powders / other solids that are capable of undergoing a change of condition, such as being fusible. In such examples, the granules / powders / other solids can flow into some materials with a plurality of interstices (like a network of voids). For example, a foam can be fixed in a container with walls; an additive powder is agitated into the plurality of interstices (like a network of voids) of the foam, as well as any spaces between the foam and the container walls; the foam with powder additive is thus placed in a packed and supported condition so that the foam and the additive can be molded; before the molded foam is agitated (such as after removal from the container) to remove the powder additive, the application of heat to the packed and supported foam will allow the granules / powders / other solids on the outer surfaces of the composite to fuse and create a partial or complete seal of the granules / powders / other solids and the foam composite.Similarly, the bottom surface can be fused to adhere to a work surface, for example. The nominal advantages of using granules / powders / other solids that can flow into some materials with a plurality of interstices (like a network of voids) are: a possible reduction in energy requirements without the need for substantial heating, as the powder can be vibrated in and vibrated out or fused out if necessary; faster processing time, as the additive does not require cooling; and little or no change in the size of the filled foam and the empty foam, as there is no thermal expansion.

[0121] • liquids that can be hardened or can be arranged and oriented to be more rigid by other means (e.g., ferrofluids; liquids that harden in response to a stimulus and return to being liquid without; starch solutions left to dry or adjust using heat; proteins such as gelatin / collagen presented in solution form that then undergoes intermolecular gelation). Petition 870220091681, dated 06 / 10 / 2022, pp. 127 / 177 22 / 52

[0122] Preferably, the additive will be a wax or a wax-like compound.

[0123] As used in this document, the expression “wax or wax-like compound” refers to a compound that is sufficiently solid, hard, and / or rigid above the freezing point of water (0 °C at standard atmospheric pressure, 101.325 kPa) to facilitate the execution of the method of the present invention by enabling the production of a desirable molded material, but which melts or softens without decomposing at temperatures above about 60 °C (such as above about 50 °C, or above about 40 °C). More typically, “wax or wax-like compound” refers to a compound that is generally solid, hard, and / or rigid above 15 °C (such as above 20 °C), but melts or softens without decomposing at temperatures above about 60 °C (or above about 50 °C, or above about 40 °C).Just as an example, such a wax or wax-like compound is a greasy additive that flows at > 25 °C, becomes almost a gel just below 25 °C, and can be considered machinable (albeit of low quality) at any temperature below that, but cooling below 0 °C would improve machining results. An example of such a greasy additive is a partially hydrogenated oil that is a paste or gel-like at 25 °C but becomes fluid above that so that it can permeate a foam. Such an additive remains stable in the foam at 25 °C and can provide an increasingly machinable result with decreasing temperature. Below 0 °C it can be as rigid as paraffin wax at 25 °C. To be contrasted with water, such a greasy additive will be sufficiently contained in the voids of the foam above the freezing point of the additive, even at a machining temperature of 25 °C.

[0124] Waxes are generally organic in nature (usually aliphatic hydrocarbons) and insoluble in water at room temperature. Waxes can be wettable with water and can form creams, gels and / or pastes in some solvents, such as non-polar organic solvents. Petition 870220091681, dated 06 / 10 / 2022, pp. 128 / 177 23 / 52 Waxes can dissolve in some non-polar organic solvents, usually with the addition of heat. Waxes can spontaneously emulsify in the presence of some liquids to form microemulsions and / or can form emulsions with some liquids in the presence of surfactant(s).

[0125] Waxes can have melting points ranging from about 40 °C to about 150 °C. In this sense, melting can also occur to a sufficient degree below 40 °C to facilitate incorporation into the plurality of interstices (like a network of voids) of the material. It will be understood that incorporation can be achieved while only a portion of the wax is substantially liquid, the remaining portion being microcrystalline, for example.

[0126] Waxes can also be defined by viscosity. Viscosity measures a material's internal resistance to flow, where a material with high viscosity is considered "thicker" and less fluid than a material with low viscosity. The melt viscosity of waxes can range from low to high and typically depends on the wax's molecular weight, crystallinity, and whether or not the wax is oxidized or copolymerized. Increasing the molecular weight and density of the wax increases the wax's melt viscosity, and increasing the wax's crystallinity decreases the melt viscosity. The friability of a wax, namely its affinity to reduce particle size by mechanical forces, increases with higher crystallinity and decreases with increasing density and molecular weight of a wax. The melt viscosity of waxes above their melting point is typically low.

[0127] Suitable waxes include both natural and synthetic waxes. Suitable waxes may include:

[0128] · animal waxes (such as beeswax, Chinese wax, shellac wax, sperm wax and wool (lanolin));

[0129] • hydrogenated vegetable waxes and vegetable oils (such as laurel wax, carnauba wax, castor wax, esparto wax, wax Petition 870220091681, dated 06 / 10 / 2022, pp. 129 / 177 24 / 52 Japanese, jojoba oil wax, sea urchin wax, rice bran wax, soy wax and hydrogenated vegetable wax oils - particularly those that are pastes / greases at room temperature);

[0130] · mineral waxes (such as ceresin wax, montana wax, ozokerite wax and peat waxes);

[0131] · petroleum waxes (such as paraffin wax and microcrystalline waxes); and

[0132] · synthetic waxes (such as polyolefin waxes, including polyethylene and polypropylene waxes, wax-grade polytetrafluoroethylene waxes (PTFE wax-like grades), Fischer-Tropsch waxes, stearamide waxes (including ethylene bis-stearamide waxes), polymerized α-olefin waxes, substituted amide waxes (e.g., esterified or saponified substituted amide waxes), polyethers (such as polyethylene glycol, such as PEG2000) and other chemically modified waxes, such as PTFE-modified polyethylene wax)

[0133] as well as combinations of the above. Of these, preferred waxes include hydrogenated vegetable waxes (such as palm waxes and soy waxes) and polyethers (such as polyethylene glycols). Hydrogenated vegetable oils and lanolin solid fractions are especially preferred for the environmental and sustainable benefits they provide to the methods and products of the present invention. Otherwise, paraffin, microcrystalline, and a variety of synthetic waxes are preferable.

[0134] It will also be appreciated that many other additives, such as sugars, sugar alcohols, salts, iron powder, are also preferred from an environmental / sustainability / resource recyclability perspective.

[0135] Other examples of additives include dry ferrous powder or a composition containing ferrous particles (such as a colloid) whose properties can be modulated by magnetic stimulation to orient themselves in a way that stiffens the foam once incorporated. Other examples of additives include: non-Newtonian material that stiffens in response Petition 870220091681, dated 06 / 10 / 2022, pp. 130 / 177 25 / 52 to a stimulus, such as high-frequency mechanical waves; or a liquid crystal that organizes itself after electrical stimulation to a hardened state. These examples can allow the modulation of additive properties and increase the ease of additive removal.

[0136] Specific examples of additives that have been tested in the processes described in this document include the following, which are listed along with their perceived advantages:

[0137] · PEG1000-3000 - hardness, machinability, reduction of airborne particles, melting point, water solubility

[0138] · PEG3000-20000 - hardness, machinability, reduction of airborne particles, melting point, water solubility

[0139] · Paraffin wax - hardness, machinability, reduction of airborne particles, melting point

[0140] · Additives that possess additional qualities related to sustainability, renewability, and environmental impact include the following:

[0141] Xylitol, Erythritol, Sorbitol; eutectics of Erythritol / Xylitol, Erythritol / Sorbitol, Sorbitol / Xylitol - hardness, melting point, machinability, water solubility

[0142] Behentrimonium Methosulfate 25, Glyceryl monostearate, Stearic acid - hardness, melting point, machinability, reduction of airborne particles.

[0143] Sodium acetate trihydrate - hardness, melting point, machinability, water solubility

[0144] Soy, palm, castor waxes and mixtures hardness, melting point, machinability, reduction of airborne particles

[0145] Isosorbide and 1,6-Hexanediol - hardness, point Petition 870220091681, dated 06 / 10 / 2022, pp. 131 / 177 26 / 52 melting point, machinability, reduction of airborne particles.

[0146] Starch / water mixtures - water solubility, machinability, reduction of airborne particles

[0147] Iron powder - hardness, machinability

[0148] · If the intention is to swell the material with a plurality of interstices (like a network of voids), such as foam (like polyurethane), for machining, then the following non-exhaustive list of additives is preferred:

[0149] Trimethyl citrate, Pantolactone (racemic), Diacetone Acrylamide, Methyl Nicotinate - hardness, melting point, machinability, water solubility

[0150] Crotonic Acid - hardness, melting point, machinability, water solubility and precipitates from a cold solution

[0151] As used in this document, the term “contact” in the expression “contact the material with an additive so that at least a portion of the additive is incorporated within at least a portion of the” plurality of interstices (such as a network of voids) of the material refers to any process by which the material and the additive are brought into intimate contact so that at least a portion of the additive is incorporated in such a manner. In this context, the term "portion" may refer to at least 5%, as well as at least 10%, as well as at least 15%, as well as at least 20%, as well as at least 25%, as well as at least 30%, as well as at least 35%, as well as at least 40%, as well as at least 45%, as well as at least 50%, as well as at least 55%, as well as at least 60%, as well as at least 65%, as well as at least 70%, as well as at least 75%, as well as at least 80%, as well as at least 85%, as well as at least 90%, as well as at least 95%.The material may or may not be completely saturated (100% incorporation of additive into the interstices) with the additive. This process may involve the use of any one or more of the following: pouring; immersion; agitation; vibration; use of reduced pressure (such as by applying vacuum); use. Petition 870220091681, dated 06 / 10 / 2022, pp. 132 / 177 27 / 52 of increased pressure. Such methods may make use of a combination of such techniques.

[0152] The use of reduced pressure may involve placing the material and additive in a fixed-volume vacuum chamber or in a variable-volume vacuum chamber (such as a bag), after which the chamber pressure is reduced, thereby causing the gas incorporated in the material to expand and escape from the material to be replaced by the additive. In one embodiment, a foam material is placed in a bag and the gaseous contents of the bag are removed by vacuum and the foam is compressed, before an additive can be introduced into the vacuum chamber as the foam expands and / or causing the foam to expand to incorporate the additive. The additive can be introduced into the vacuum chamber through the same port or a separate port, such that the vacuum in the chamber is reduced and the material expands (such as using a peristaltic pump).This vacuum method can be particularly useful when incorporating molten wax within a foam, although it is usually desirable to ensure incomplete saturation in such an embodiment. In some embodiments, the material with the plurality of interstices (like a network of voids), for example, foam, and the solid additive are placed inside a vacuum bag; a vacuum is applied to the bag through an opening that compresses the material and extracts all or part of the air; the outlet is subsequently sealed and the vacuum bag is heated (such as being placed in a heated liquid) to melt the additive, thus causing the molten additive to be drawn into the material as it melts, resulting in a fully expanded material with additive when the contents of the bag are returned to atmospheric pressure.Some nominal advantages of this method include: a simple equipment setup that requires less space and reduces spillage and exposure to risks; improved repeatability and consistency by measuring the weight of additive needed; and enhanced reliability with fewer tubes requiring heating to prevent premature hardening and blockages. Petition 870220091681, dated 06 / 10 / 2022, pp. 133 / 177 28 / 52

[0153] In some embodiments, a molded vacuum bag can be used to act as a template so that material with interstices (e.g., voids, e.g., foam) can cool and harden without being removed from the bag. The vacuum bag itself may be molded or consist of one or more solid members with a mold (such as: two solid plates with a silicone reinforcement or footing joining the two; or a plate with a vacuum sheet sealed around the perimeter). When vacuum is applied, it provides a flat pressure across the material and when the vacuum is released, it provides a flat surface for the material to cool. In some cases, a bottom plate may be present as the intended working surface and placed on the machine bed for molding. Alternatively, one or more of the plates may be molded (as a template).The nominal advantages are: simple equipment installation requiring less space and reduced spillage and exposure to hazards; consistently flat and square material (e.g., foam) as it hardens; reduced deformation if using a two-plate configuration on thinner sheets, as it can be gently pressed / restrained from distortion; and / or a possible reduction in process time and energy requirements for specific requirements (if only smaller parts are needed or if it is not possible to prepare large stocks of slabs).

[0154] In some embodiments, the additive can be used to expand the material with a plurality of interstices (like a network of voids). For example: the material (e.g., foam) can come into contact with an additive that swells the material; the additive hardens so that the material is now in a swollen state; the material is molded; and the additive is removed and the material returns to its original size. The method offers the nominal advantage of being able to improve the infiltration of very fine foams by increasing the overall size of the material and therefore the flow of additive into the material; and improving machining resolution by molding at an enlarged size. Petition 870220091681, dated 06 / 10 / 2022, pp. 134 / 177 29 / 52

[0155] Another variation in the use of reduced pressure is the application of force to an elastic or viscoelastic material with a plurality of interstices (such as a network of voids) so that the material compresses and expels at least a portion of the contents of the material's voids. After the relaxation of this force, and in the presence of an additive, the material expands, thus incorporating at least a portion of the additive into the material. For example, a foam can be submerged in a bath or bag of liquid wax; the foam can be compressed so as to expel any incorporated gas and then allowed to expand to incorporate some of the liquid wax from the bath. In some embodiments, it is desirable to saturate the material with additive, while in other embodiments it is desirable to only partially saturate the material with additive. In this example, the amount of gas that is expelled can vary depending on the degree of compression of the material.The amount of gas present in the material can also be modulated by various techniques, including removing the partially compressed material from the bath before allowing it to fully expand. Another technique involves only partially compressing the material so that the product material incorporates a portion of additive and a portion of gas. In yet another technique, a material is allowed to preferentially and unevenly absorb from, for example, one aspect of the material so that, for instance, the material incorporates additive on one face to a greater degree than other parts of the material. Such methods have been found to allow the user to produce a material that incorporates a desired ratio of gas to wax. Similar method(s) may be applied to other materials and / or additives.It will be understood that the ability to compress elastic or viscoelastic material with a plurality of interstices (like a network of voids) represents a significant departure from previous methods used on non-elastic or non-viscoelastic materials.

[0156] Advantageously, the method of the present invention allows modulation of the amount of additive to be incorporated and also modulation of where the additive is incorporated into the material. For example, Petition 870220091681, dated 06 / 10 / 2022, pp. 135 / 177 30 / 52 The additive can be focused on specific areas to enhance the method and / or product. For example, a quantity of wax can be incorporated within a foam to a degree sufficient to merely coat the surfaces of the voids and immobilize most of the foam. As another example, a quantity of wax can be incorporated only into the top machining layer of the foam, thus substantially stiffening the material and providing the highest quality surface finish. Modulating the amount of additive that is incorporated into the material allows for a decrease in the amount of additive required, potentially facilitating easier removal of the additive.

[0157] Although the process of contacting the material with the additive has been extensively described for a foam and a wax, the use of non-liquid additives is also contemplated. For example, additives that are granular, powdered or mixtures thereof, particularly those that can flow, can be incorporated into the material by pouring, or even by using reduced pressure, particularly when the additive can be transported by air.

[0158] As used in this document, the expression “subjecting the material to conditions such that at least a portion of the incorporated additive solidifies, hardens and / or stiffens” refers to providing one or more external stimuli to modify the conditions experienced by the material and additive. Examples of such stimuli include magnetic, electrical, thermal, chemical, mechanical and electromagnetic.

[0159] Typically the stimulus will be a thermal stimulus, for example a stimulus that leads to a reduction in the temperature of the additive. For example, the stimulus may simply be a reduction in the ambient temperature in which the additive (and material incorporating the additive) is located, so that the temperature of the additive reduces in such a way that the additive solidifies, hardens and / or stiffens, as would be expected when a wax changes from a liquid state to a substantially solid state. Petition 870220091681, dated 06 / 10 / 2022, pp. 136 / 177 31 / 52

[0160] As indicated above, examples of other stimuli include: magnetic stimulation; the application of force (including shear) such as by the application of high-frequency mechanical waves; or the application of electrical stimulation.

[0161] In some embodiments, it may be desirable to further manipulate the material before molding. Examples of manipulation may include pressing, engraving, shaping, bending, joining, splicing, and / or inserting pieces of material before the additive is hardened or introduced. The objectives of which may include pre-forming molds (as a template), smooth machining of multiple joined / spliced ​​material pieces, or pressing / compressing the material to reduce the amount of additive required. For example, pre-forming or compressing the material with an additive can be used to simplify and speed up some operations.In such methods, for example, compression can typically occur with a positive (and mirror image) template if it replicates a mold – for example, to produce a foam hemisphere, the template would be a positive hemisphere, and the highest point of the hemisphere when pressed into the foam would be the lowest / most compressed part of the foam, thus creating a negative impression on the foam. The process would then include the steps of: placing a foam in contact with an additive and then placing it in a template that compresses and imprints a hemisphere in the center; the foam and additive harden in the template; the hemisphere imprint is substantially lower than the rest of the foam and therefore excludes it from the cutting operation; if the foam in this case is only milled or planed to the depth of the imprint, the resulting foam, when the additive is removed, will have a protruding positive hemisphere mold higher than the rest of the foam.In another embodiment, the process includes the steps of: stamping a sheet of foam with liquid additive onto a positive pattern; hardening the additive and maintaining the compressed or embossed state; cutting the material to remove the uncompressed portion; heating the additive and removing the additive to reveal a positive replication of the pattern. Such processes may be... Petition 870220091681, dated 06 / 10 / 2022, pp. 137 / 177 32 / 52 advantageous for quickly creating standard molds or the overall mold of the article before progressing to further molding, or for easily creating textures that might otherwise take time to form. This can be used as an alternative to foam convolution machines, but with the additive capable of holding the mold until it is removed. Additional benefits are believed to be: more complex molds can be formed; further machining can be done on the compressed foam; it is not restricted to roller compression; the foam slab stock can be kept at room temperature with a compressed mold or texture ready for further molding; it allows mass production of items using the original method. Possible additional advantages of this are that the pre-compressed foam blanks can contain an impression of, for example, a standard wheelchair seat.Thus, a cutting pass can provide the basic mold followed by a calculated pass to customize the mold for a specific customer. This would effectively reduce the required depth of cut, increase speed, and reduce the volume of additive. Furthermore, the compressed foam is not permanently formed until the foam material is removed by machining. For example, a foam sheet with a rolled embossing can be heated and the foam returned to a normal square foam sheet. If cut horizontally, it would produce a rolled sheet. Knowing the compressed mold and dimensions, it is further possible to mold the foam beyond the printed mold by offsetting, so that selected convolution peaks can be removed by machining the compressed portions; or convolution troughs can be removed by not machining the uncompressed portions.In general, these processes allow the core methods of the present invention to be extended from customized manufacturing to higher volume mass production with the addition of flexibility and customization. In such embodiments, the compression process can be achieved by, for example: compression before cooling; partial saturation and cooling of the foam, followed by pressing and bonding. Petition 870220091681, dated 06 / 10 / 2022, pp. 138 / 177 33 / 52 of the compressed cells; use of a cold press to quickly harden portions of the foam. Alternatively, this can be done using variations of the additive described above with their respective advantages (powders, waxes, dry powder additives, etc.). As can be seen, these processes can be combined with the core methods of the invention using compression / etching on one side and performing more complex machining on the opposite side.

[0162] Before and / or during the material molding process, the material will normally be held firmly in place so that the molding device, for example, is mobile and moves around the immobilized material. Advantageously, certain embodiments of the present invention allow the material to be securely fixed to a surface in such a way that the material can also be removed from the surface with relative ease upon completion of the molding process. In particular, a heated / cooled working surface can be used, such as that provided by hydronic heat transfer.When the additive solidifies, hardens, and / or stiffens as a result of being subjected to a reduction in its temperature, like a wax, a foam incorporating this additive can be positioned on the surface at a specific elevated temperature (typically exceeding the melting point of the wax) and fixed to the surface by reducing the surface temperature to, for example, below the melting point of the wax. A material subjected to these conditions has been found to remain sufficiently secure to the surface to allow the molding process to occur. At the end of the molding process, the surface temperature can be increased, and the material will detach and can be removed and / or repositioned. Such techniques provide a significant advantage over previously published processes that require the use of clamps, strong adhesives (such as superglue), which are known to damage the material and are limited in possible machining geometry.

[0163] As used in this document, the expression “shaping the material” refers to any process by which the material Petition 870220091681, dated 06 / 10 / 2022, pp. 139 / 177 34 / 52 is modified from one mold to a different mold. Generally, the present invention is best suited for subtractive molding processes, including hand molding and machining. Examples of machining processes include computer numerical control (CNC) machining, such as contour machining. Such machining includes the use of lathes, milling machines, lathe-milling machines, multi-axis robotic arms, multi-axis water jets, lasers, hot wire machining, sonic knives, reciprocating blades / saws, knives, and ablation tools.

[0164] Preferably, the machining process will utilize CNC machining, an example of subtractive machining, with a definable tool depth or end. Such processes with a definable tool depth or end typically include spindle (milling machine and milling lathe) or a combination of spindle and non-rotating feed tool (mechanical lathe and milling lathe), ultrasonic tool (non-rotating cutter), reciprocating tool (reciprocating and concentric cutters), concentric rotary tool, grinding / sanding / scraping / deburring tool.

[0165] Processes with a definable depth or tool end typically exclude processes such as lasers, water jets, plasma cutters and air jets and band saws, chainsaws and wire cutters that do not cut at a point or on the radii of a guide.

[0166] As used in this document, the expression “remove at least a portion” of the incorporated additive refers to processes such as the following:

[0167] • agitate (e.g., shaking, vibrating, compressing (which may be slow or fast; and may be repeated several times in a compression / expansion cycle), or the use of centrifugal forces) the material incorporating the additive so that at least a portion of the additive is fragmented and becomes unincorporated, a phase in which the unincorporated additive can be isolated;

[0168] • place the material incorporating the additive in Petition 870220091681, dated 06 / 10 / 2022, pp. 140 / 177 35 / 52 a liquid bath, followed by optional agitation (e.g., shaking, vibration, compression, or use of centrifugal forces). The liquid bath may be at a different temperature (e.g., warmer) than the material before it is placed in the bath. The liquid may be immiscible with the additive. In one embodiment, the additive (e.g., wax) melts and becomes unincorporated and separates from the material. For example:

[0169] The material incorporating the wax can be placed in a warm water bath and agitated so that the wax melts, separates from the material and separates from the warm water, accumulating on the surface of the warm water;

[0170] The material incorporating the wax may also optionally incorporate a surfactant mixed with the wax. Once placed in a water bath (optionally warm) and stirred, the wax melts and the surfactant solvates, allowing the formation of an emulsion of the wax and surfactant;

[0171] The material incorporating the wax can be placed in a water bath (optionally warm) incorporating a surfactant and the material can be agitated so that the wax (optionally melts) separates from the material and emulsifies in the water;

[0172] The material incorporating the wax can be placed in a solvent bath (optionally warm) (which is capable of solvating the wax) and the material can be agitated so that the wax (optionally melts) separates from the material and dissolves in the solvent.

[0173] · agitate (e.g., shaking, vibrating, compressing (which may be slow or fast; and may be repeated several times in a compression / expansion cycle), or using centrifugal forces) the material while the material is exposed to heat so that at least a portion of the incorporated additive melts and drains from the material. For example:

[0174] In one of these modalities, this process can be carried out by applying heat to the material incorporating the additive in such a way Petition 870220091681, dated 06 / 10 / 2022, pp. 141 / 177 36 / 52 that at least a portion of the additive melts before compressing the material to expel most of the additive from the material;

[0175] o In another of these modes, both heat and compression can be applied continuously until the desired level of additive is removed;

[0176] In another of these embodiments, the material may be placed in a bag, the contents of which are subjected to reduced pressure by means of a vacuum, before the bag is subjected to heat to melt the additive which may then be removed from the bag under vacuum.

[0177] It will be understood that any of the above methods can be used to effect a partial or complete removal of the additive from the material. Typically, such methods will effect a partial removal of the additive from the material. In such embodiments, it may be desirable to remove the residual additive using a secondary removal process. Such secondary processes include any one or more of the above removal techniques. For example:

[0178] · The application of solvent to the material incorporating residual additive, optionally combined with agitation (e.g., shaking, vibration, compression or use of centrifugal forces).

[0179] The step of removing at least a portion of the incorporated additive may precede an additional step of recovering the surfactant, wax, and water for reuse.

[0180] In the twelfth and thirteenth aspects, the invention provides a method for forming a molded elastic or viscoelastic material having a plurality of interstices (like a network of voids), the method including the steps of:

[0181] i. in a container, place an additive in contact with a resin capable of being cured to form an elastic or viscoelastic material to form a mixture;

[0182] ii. degas the mixture, such as by vacuum, Petition 870220091681, dated 06 / 10 / 2022, pp. 142 / 177 37 / 52 and / or mix the mixture to form a homogeneous blend;

[0183] iii. cure the resin in order to form an elastic or viscoelastic material incorporating at least part of the additive;

[0184] iv. molding the material incorporating the additive in order to form a molded material incorporating the additive; and

[0185] v. optionally remove at least a portion of the incorporated additive from the molded material that incorporates the additive,

[0186] wherein the additive is not water and the additive solidifies, hardens and / or stiffens when subjected to changes in selected conditions among: thermal, magnetic, electrical, chemical and / or electromagnetic.

[0187] This aspect differs in some respects from the other aspects in that the elastic or viscoelastic material is formed from a resin that is already in contact with the additive. However, it shares several similarities. In particular, the molded elastic or viscoelastic material that the method forms is potentially indistinguishable from a molded elastic or viscoelastic material formed by the other methods disclosed in this document. The resin method may offer certain advantages / disadvantages over methods that contact the additive with the elastic or viscoelastic material.

[0188] The resin can be shrinkable (by heat, electromagnetic radiation, electro, etc.) so that the foam can be molded to a larger size and then shrunk. The nominal advantages of this method include allowing the molding of microstructures that might otherwise be too small relative to the machine; and / or improving the accuracy of the machine equipment – ​​for example, molding to twice the size would effectively double the machining tolerance when the material is finally shrunk. This resin technique can be applied to: developing implantables; soft robotics; reproduction of very small biological structures. In the case of soft robotics, the resin can be reversibly controllable, providing new types of pumps. Petition 870220091681, dated 06 / 10 / 2022, pp. 143 / 177 38 / 52 multicellular or muscle analogues. This technique can also be combined with 3D printing whereby: the additive is 3D printed to form the desired interstices (such as void networks) and coated in resin; and the additive and resin are 3D printed. As can be seen, this tenth aspect is fundamentally different from shrink resin 3D printing per se, since this method does not involve the use of an additive defined in this document and a subsequent machining step.

[0189] In some embodiments, the additive may be aerated before the sphere is formed, have a sufficiently low vapor pressure, or contain a mixture that may release gas.In these cases, the process may include the following steps: combining the additive (such as spheres) with a resin; curing the resin; placing the cured resin-containing additive with a sealed film around its exterior in a vacuum chamber to produce a cured resin with the additive in the form of an additive incorporating foam as space supports; increasing the temperature of the vacuum chamber so that the additive is melted and the pressure is reduced (in this event, in the case of the aerated additive, the trapped air expands and therefore expands the cells in the foam); cooling and hardening the additive to retain the expanded state of the foam at normal atmospheric pressure; molding the expanded foam to break the sealed outer film; heating the material so that the additive can be removed and the foam returns to its original size.

[0190] Many of the above-mentioned processes for additive removal advantageously avoid the use of harmful solvents (compared to previously published methods), thus reducing the risks, storage, and costs associated with solvents in previously published methods.

[0191] When the solvent can be avoided, the present invention increases the variety of materials suitable for the method, since the addition and removal method does not damage the material, whereas solvent compatibility is not consistent across all materials (especially Petition 870220091681, dated 06 / 10 / 2022, pp. 144 / 177 39 / 52 foams).

[0192] An additional advantage is the ease of emulsification, particularly when the additive is incorporated into a mixture by addition with a surfactant, where the use of agitation combined with the proximity of the surfactant to the additive removes the problems of solvent penetration if the deeply incorporated additive is removed, as can be found in much larger articles.

[0193] The present invention provides numerous advantages over previously published methods. Previously published methods do not address the environmental impact of their method nor disclose progressive solutions. In contrast, the present invention allows for the recovery of the additive, thus providing a progressive environmental and sustainable method. For example, the ease of extraction and recovery of the additive allows for the reuse of additive, material, and solvent (including water) in a closed-loop system. The use of additives derived from sustainable renewable resources has been found to provide improvements in environmental and sustainable impacts. An additional advantage is that the invention can be adapted to increase the adoptability, quality, time, and cost associated with storage and equipment by contracting one or more process steps out to third parties.One such approach could be licensing a third party to perform the additive incorporation step into the material in order to reduce costs, increase quality, and improve consistency. The prepared material can be delivered as needed to the parties intending to perform the material molding and additive removal. The third party can then collect the additive and prepare new material, efficiently recycling waste foam material. If necessary, the third party can perform further additive processing or reformulation. This would allow smaller entities to adopt the method and allow additive handling to be dedicated to larger entities or emerging parties specializing in additive handling and formulation, and handling of any related materials. Petition 870220091681, dated 06 / 10 / 2022, pp. 145 / 177 40 / 52 residual materials.

[0194] Another adaptation to reduce material waste facilitated by the present invention could be the preparation of molded foam blanks for machining, such as foam seat orthosis blanks that could be machined to a specific need instead of machining large quantities of a square foam block to achieve the same mold as the orthosis blank.

[0195] Another advantage of the invention is the control of particulate matter (such as dust) during machining, which eliminates the need for extraction equipment, as the additive binds to the residual material during machining, thus effectively encapsulating the particulate materials, largely eliminating airborne particles.

[0196] One advantage over other methods of producing molded materials (such as foam articles) is the reduction in storage required for storing models that require large storage areas or the reconstruction of models from CAD files.

[0197] An additional advantage is the ability to prepare the material with incorporated additive and store the prepared material for extended periods of time without the need for particular storage conditions (such as cold storage required for some previously published methods). In this way, the storage of prepared material (e.g., foam) can be done in large slabs or predetermined sizes and molds. Parts can be removed from the slabs only as needed, which increases cutting economy to reduce waste. Furthermore, the cost of equipment and space required can be further reduced by allowing third parties to prepare the material and supply it to the entity intending to mold the prepared material.

[0198] The present invention can also make use of 3D modeling. In methods that depart from traditional model-making methods, the use of minimal or non-contact 3D measurement, Petition 870220091681, dated 06 / 10 / 2022, pp. 146 / 177 41 / 52 Mapping and / or tracking can be used to produce data that can be manipulated using CAD / CAM methods and subsequently output in a form for machining. 3D measurement, mapping, and tracking can include typical medical imaging; magnetic resonance imaging (MRI), computed tomography (CT), X-ray or ultrasound or 3D scanning, motion tracking and mapping techniques, or pressure mapping and impression mapping. EXAMPLES

[0199] The following examples of the invention are not exhaustive and are provided for illustrative purposes only.

[0200] A block of flexible open-cell foam (2) (which is an example of an elastic or viscoelastic material with a network of voids) is provided to be machined. In one embodiment, the block (2) can be saturated in a template (4) for full incorporation of the additive. The template can have an open bottom (10) to allow the block to be fixed to a machine bed, or the template can have a closed bottom (12) to allow the block to be moved after incorporation of the additive, separated from the machine bed. In both cases, the block can optionally undergo partial addition / removal of any additive through the use of a plunger (16). The template can then be removed from the molded product, fixed to the machining bed (20), or separated from the machining bed (22).When the material incorporating the additive (22) is separated from the machining bed, it can be subsequently attached to the machining bed by a separate heating step to remelt part of the wax (26) and attach it to the machining bed. In another embodiment, the block (2) can be contacted with hot molten wax in a bath (6) at, for example, 50 to 80 °C, and optionally subjected to compression agitation (14) using a plunger. The foamed material can then be removed from the bath and allowed to drain off excess additive (18) when desired to allow partial saturation. An optional secondary saturation step of one aspect (one face) of the material. Petition 870220091681, dated 06 / 10 / 2022, pp. 147 / 177 42 / 52 of foam (24) can be supplied. In both cases, the foam material can be fixed to the machining surface through a separate heating step to remelt part of the wax (26) and attach it to the machining bed. In another embodiment, the block (2) can be placed in a bag (8) to which a vacuum is applied to reduce the air in the foam before hot wax is pumped in to fill the air space and uniformly saturate the foam. After removing the foam material from the bag, the foam material can be fixed to the machining surface through a separate heating step to remelt part of the wax (26) and attach it to the machining bed.

[0201] The fixed material (28) can then be machined using a series of processes. In one embodiment, the material can be machined by one-sided machining (30), the product of which can be removed from the machining bed by applying heat (34). In another embodiment, the material can be machined by two-sided machining (32) obtained by leaving an edge to create a trough. The trough (36) can be filled with wax or even a fluid wax / residue paste (44) before the top surface is leveled. The workpiece (38) can then be heated to remove the workpiece from the bed (40) before being turned and annealed (42) to the machining surface. The turned workpiece can then be machined (46) into a two-sided machined product (48) and removed from the machining bed (50).

[0202] In either embodiment, the material can be placed in a hot wax bath (52) to remelt the additive. Removal and application of agitation (compression) (54) can be performed to remove most of the wax. Alternatively, the material can be placed in a bag to which vacuum and heat are applied in order to remove the molten wax from the foam material. The finished part (58) can be washed or wax residues can be left to impart some water repellency, conditioning and / or antibacterial properties. Washing can be performed using: warm detergent (surfactant) solution in a bath; ultrasonic bath Petition 870220091681, dated 06 / 10 / 2022, pp. 148 / 177 43 / 52 using detergent and heat; continuous flow of warm water or water with detergent; warm detergent bath with agitator or compression. Alternatively, solvent can be used to recover residual wax through any of the relevant methods mentioned above.

[0203] Figure 4 shows that the methods of the invention can be applied to a multitude of molded stocks (60) as seen in Step 1A. Or to a molded blank (62) for customization or machining to tolerance; or for reworking a previously molded material as seen in Step 1B.

[0204] Figure 5 shows an example of a method of the invention. In particular, step 1C illustrates an alternative process in which the solid additive (64) is used to form voids in the resulting material when the additive is removed. Step 1 involves placing the solid additive (64) in a receptacle (66). Step 2 involves adding the bulk elastic / viscoelastic material (68). Step 3 involves degassing or mixing the aforementioned additive and bulk material, if desired, and retaining it in the original receptacle or transferring it to another receptacle(s), followed by curing, hardening, and drying of the bulk material. Step 4 involves molding the cured bulk material / additive mixture. Step 5 involves completing the molding or other molding operations to obtain the desired shape. Step 6 involves heating (70) the additive, which can be done in various ways with or without a vacuum bag.Step 7 involves removing the additive by vacuum (72) and / or by compression (74). Step 8 provides the finished article. Further cleaning or treatment may be carried out if desired.

[0205] As a particular example of the method, molten paraffin wax is dripped at a constant rate into a cold water bath to cool rapidly and form approximately spherical molded spheres. The paraffin is dripped from a height sufficient to form individual droplets, but not so high as to produce irregular molded pieces (e.g., Petition 870220091681, dated 06 / 10 / 2022, pp. 149 / 177 44 / 52 flat splash molds). The bath with a constant circular flow transports the paraffin beads away from the release point to minimize melting and aggregation of the beads. The paraffin beads are removed from the bath and dried. The beads are placed in a rectangular container and a two-component addition-cure silicone is prepared and added to the container. The container with the uncured silicone and beads is placed in a vacuum chamber and subjected to reduced pressure to remove unwanted pockets of trapped air. The container is removed from the vacuum chamber and the silicone is left to cure. Once cured, the silicone with paraffin beads can be removed from the container resulting in a rectangular silicone block with embedded paraffin beads. The rectangular block is fixed to the workbed of a CNC router and machined into the desired mold.The machining process breaks down the outer silicone film, allowing for the removal of the paraffin additive. The molded part is heated to melt and remove the paraffin with the addition of compression. A detergent wash can be used to remove unwanted residue. The final product is a molded, elastic, open-cell silicone foam.

[0206] In some embodiments, the additive spheres can be selected from a variety of suitable materials, including: waxes, wax-like polymers, salts, sugars, sugar alcohols, etc. The silicone “resin” as described can be replaced by a variety of polymers characterized by properties such as: elastic / viscoelastic, resilient, soft, flexible, etc. “Curing” in a descriptive sense can describe a variety of known methods depending on the base material, for example: drying, electromagnetic radiation crosslinking, heat, or synthesis.

[0207] Additionally, the additive may have secondary properties or be manipulated in order to alter the final product. For example, an additive may be beaten to incorporate air into the mixture before producing the molded spheres, so that the solid molded spheres Petition 870220091681, dated 06 / 10 / 2022, pp. 150 / 177 45 / 52 contain a portion of air throughout. The silicone curing process around the spheres is then carried out, followed by melting the paraffin sphere(s) by heating the cured silicone. The heated silicone is then placed in a vacuum chamber. A vacuum is applied, and the air bubbles dispersed throughout the additive expand. The film formed around the exterior of the silicone prevents air from escaping from the silicone material block, thus causing it to expand in size. The silicone part is then cooled in an expanded state to maintain its shape. The part is then machined, and the additive is reheated and removed, allowing the silicone part to return to its original size. This process preferably involves the following events:

[0208] · The additive must be formulated or melted in such a way that air bubbles do not aggregate and prevent the maintenance of the expanded state;

[0209] · The silicone expands in a uniform or predictable manner and without breaking the outer film;

[0210] • The additive's resistance when expanded is sufficient to maintain the expanded state of the silicone for machining.

[0211] Figure 6 shows various embodiments of the invention method, including the step of contacting a foam with an additive:

[0212] Stage 2A includes several substages:

[0213] • Substep 1 involves placing the foam (76) from Figure 4 (Step 1A or IB) into a vacuum bag (78);

[0214] • Substep 2 involves the partial or total removal of air to compress the foam;

[0215] • Substep 3 involves introducing the additive (80) to come into contact with the foam. This can be done by the negative pressure of the expanding foam or by injection by other means, such as a pump, syringe or other suitable means; Petition 870220091681, dated 06 / 10 / 2022, pp. 151 / 177 46 / 52

[0216] · Substep 4 provides the resulting foam with the additive.

[0217] Stage 2B includes several substages:

[0218] · Substep 1 involves a foam (82) situated in a container containing the additive (84; as an example the additive is heated to the liquid state) and a suitable press (86);

[0219] · Substep 2 involves compressing the foam to expel all or part of the air inside;

[0220] • Substep 3 involves releasing the press to allow the additive to be pulled into the cells.

[0221] Stage 2C includes several substages:

[0222] • Substep 1 involves placing foam (88) in a suitable vacuum bag (90) or similar container with the additive (92) in solid state;

[0223] • Substep 2 involves applying vacuum to remove air and compress the foam, resulting in a solid additive and compressed foam;

[0224] • Substep 3 involves heating the additive and foam by a suitable means while it is still air-free or partially air-free;

[0225] • Substep 4 involves extracting the additive (as it becomes liquid) from the compressed foam, resulting in an uncompressed foam with the additive incorporated.

[0226] Figure 7 shows a process similar to that shown in Step 2B, where the container acts as a model:

[0227] Stage 2D includes several substages:

[0228] • Substep 1 involves placing a foam (94) in a container (96) containing the additive (98; as an example the additive is heated to the liquid state) and a suitable press (100);

[0229] • Substep 2 involves the compression of Petition 870220091681, dated 06 / 10 / 2022, pp. 152 / 177 47 / 52 foam to expel all or part of the air inside;

[0230] · Substep 3 involves releasing the press to allow the additive to be drawn into the cells, followed by cooling the foam / additive inside the container;

[0231] • Substep 4A shows that the container or the base of the container is the intended work bed or a bed to be fixed to a machine bed. The side (102) of said container may optionally be removed.

[0232] • Substep 4B involves removing the hardened foam (104) from the container.

[0233] Figure 8 shows a process in which solid granules, powders, etc. are the additive and optional or, if necessary, can be manipulated by external stimuli - whether solid or not.

[0234] Stage 2E includes several substages:

[0235] • Substep 1 involves applying an additive (106) as a solid granule to the foam (108) located in a container that is agitated to facilitate the movement of the additive in the foam.

[0236] • Substep 2 shows the additive inside the foam.

[0237] • Substep 3A involves shaping the foam and additive within the container into a substantially more solid composite.

[0238] • Substep 3B shows the additive undergoing magnetorheological change, whereby the individual granules are held substantially firmer or prevented from moving by means of a magnetic field being applied in the vicinity of the container.

[0239] • Substep 3C shows the additive undergoing magnetorheological change so that the individual granules are held substantially more firmly or prevented from moving in a work bed or machine bed by means of a magnetic field.

[0240] • Sub-step 4 shows the molded foam Petition 870220091681, dated 06 / 10 / 2022, pp. 153 / 177 48 / 52 being agitated to remove the additive, which can be further enhanced by applying a magnetic field to help extract and collect the additive while additionally separating residual material from the additive. This can be done in a bath or dried elsewhere.

[0241] Figure 9 shows how the addition or removal of heat can be used to modify the properties of the additive.

[0242] Stage 3A includes several substages:

[0243] · Substep 1 involves concentrating the additive (110) in the desired region of the foam by: cooling the additive and foam (112) by orientation; cooling with substantially more additive in the region of interest; or reapplying to the desired region of already hardened foam.

[0244] • In sub-step 2 (in the case of a reduced additive requirement) the additive can be concentrated in the area to be machined to improve molding.

[0245] In Step 3B, the excess additive (114) can flow out or be compressed into the desired quantity.

[0246] In Step 4A, the foam can be left to harden and adhere to the work surface.

[0247] In Step 4B, the foam can be hardened in a vacuum bag or other suitable container (including those from step 3A) that can be molded to form a template.

[0248] In Step 4C, the foam can be hardened by other means before being affixed to a work surface.

[0249] Stage 5 includes the following sub-stages:

[0250] • Substep 1 involves fixing the hardened foam to the work surface by heating the work surface or applying a molten additive to the work surface, with or without a heated surface, to adhere the foam.

[0251] • Substep 2 involves cooling the work surface to adhere the foam or allowing it to cool without additional cooling. Petition 870220091681, dated 06 / 10 / 2022, pp. 154 / 177 49 / 52 Alternatively, the foam can be fixed by any other means, for example, standard work supports such as chucks, bench vises, clamps, vacuum holders.

[0252] Figure 10 shows, by way of example, how the process in Figure 9 can be continued.

[0253]

[0254] Step 6A(1) involves shaping the foam (116). Step 6B illustrates a method for multi-sided machining, including the following sub-steps:

[0255] · Substep 1 involves applying additive (118) to previously created molded surfaces or channels followed by hardening.

[0256] Substep 2 involves facing the top so that it is flat or shaped (as for other assembly methods, such as dowels, bench vises, or interlocking members).

[0257] • In substep 3 (in the case of foam affixed by an additive) the bed is heated and the workpiece (120) is repositioned.

[0258] • In substep 4 (in the case of additive fixation) the workpiece is positioned and the work bed is cooled.

[0259] • Substep 5 involves shaping the repositioned workpiece

[0260] • Substep 7 involves removing the molded foam from the work surface by applying heat.

[0261]

[0262]

[0263] Figure 11 illustrates the removal of the additive. Step 8A includes the following substeps: • Substep 1 involves heating the molded foam (122) by any suitable means, for example, by conduction in a container of water or liquid additive or by radiant heat.

[0264] • Substeps 2, 3, 4 show that the heated molded foam is pressed by a suitable means.

[0265] Step 8B includes the following substeps: Petition 870220091681, dated 06 / 10 / 2022, pp. 155 / 177 50 / 52

[0266] · Substep 1 shows the molded foam (124) situated in a suitable vacuum bag or arrangement as described in the description preface. The molded foam is heated by suitable means as described in Step 8A. Vacuum may be applied before and during heating to improve this step.

[0267] · Substeps 2 and 3 show the vacuum being applied to remove the additive and then the vacuum being released, allowing the foam to expand. Optionally, the bag can be compressed by other means.

[0268] An additional washing or residue removal step may be desired.

[0269] Figures 12 and 13 show how the addition or removal of heat can be used to modify the properties of the additive.

[0270] Stage 2F includes several substages:

[0271] • Substep 1 involves placing a foam (126) in a container (128) containing the additive (130; as an example the additive is heated to the liquid state) and a suitable press (132);

[0272] • Substep 2 involves compressing the foam to expel all or part of the air inside;

[0273] • Substep 3 involves releasing the press to allow the additive to be pulled into the cells;

[0274] • Substep 4 involves compressing the foam with a model (134);

[0275] • Substep 5 involves cooling the foam / additive while compressed by the model inside the vessel;

[0276] • Sub-step 6 shows the hardened foam with the model impression;

[0277] • Substep 7.8 involves removing the foam material using a face machining (molding) operation;

[0278] • Substep 9 involves heating the Petition 870220091681, dated 06 / 10 / 2022, pp. 156 / 177 51 / 52 molded foam by any suitable means, for example, by conduction in a container of water or liquid additive or by radiant heat;

[0279] · Substep 10 involves compressing the heated foam / additive;

[0280] • Substep 11 shows the resulting foam displaying the mold of the model.

[0281] Unless the context clearly requires otherwise, throughout the description and claims, the words “include”, “comprising” and the like should be interpreted in an inclusive sense as opposed to an exclusive or exhaustive sense, i.e., in the sense of “including, but not limited to”.

[0282] Full disclosures of all applications, patents and publications cited above and below, if any, are incorporated herein by reference.

[0283] Reference to any prior art in this descriptive report is not, and should not be taken as, an acknowledgment or any form of suggestion that such prior art is part of the common general knowledge in the field of practice in any country in the world.

[0284] The invention may also be broadly said to consist of the parts, elements and features referred to or indicated in the descriptive report of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

[0285] When the preceding description refers to integers or components having known equivalents thereof, those integers are incorporated into this document as if established individually.

[0286] It should be noted that various changes and modifications to the presently preferred embodiments described in this document will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention. Petition 870220091681, dated 06 / 10 / 2022, pp. 157 / 177 52 / 52 and without diminishing its concomitant advantages. It is therefore intended that such alterations and modifications be included within the present invention. Petition 870220091681, dated 06 / 10 / 2022, pp. 158 / 177

Claims

1 / 2 CLAIMS 1. A method for molding an elastic or viscoelastic material with a plurality of interstices, wherein the method is characterized in that it includes the steps of: i. providing an elastic or viscoelastic material with a plurality of interstices; ii. contacting the material with an additive such that at least a portion of the additive is incorporated within at least one portion of the plurality of interstices of the material; iii. subjecting the material to conditions such that at least a portion of the incorporated additive solidifies, hardens and / or stiffens; iv. molding, using a subtractive molding process, the material incorporating the solid, hard and / or rigid additive so as to form a molded material incorporating the additive, wherein the subtractive molding process is carried out using computer numerical control (CNC) machining; and v.to remove at least a portion of the incorporated additive from the molded material incorporating the additive, wherein the additive solidifies, hardens and / or stiffens at a temperature above 0 °C.

2. Method according to claim 1, characterized in that the elastic or viscoelastic material is selected from: foams and / or sponges, felts, trusses, scaffolding, rolled materials, meshes and / or webs.

3. Method according to claim 1, characterized in that the elastic or viscoelastic material is a foam.

4. Method, according to any one of claims 1 to 3, characterized in that the additive is selected from: a wax or wax-like compounds and mixtures thereof; a supersaturated crystalline solid / liquid; a liquid crystallizing compound; a non-Newtonian compound that solidifies; granules / powders / other solids that can flow into the elastic or viscoelastic material; liquids and / or solids that can be hardened or can be arranged and oriented to be more rigid by other means.

5. A method according to any one of claims 1 to 4, characterized in that the additive is a wax or a wax-like compound.

6. Use characterized by the fact that it is an additive that is solid, hard and / or rigid at a temperature above 0 °C for molding an elastic or viscoelastic material with a plurality of interstices within which the additive has been incorporated, wherein the elastic or viscoelastic material is molded by a subtractive molding process before at least a portion of the additive is removed from the elastic or viscoelastic material, wherein the subtractive molding process includes CNC machining.

7. Contoured elastic or viscoelastic material characterized in that it has a plurality of interstices, wherein at least one portion of the material has an additive incorporated into the material, wherein the additive is solid, hard and / or rigid at a temperature above 0 °C, the contoured elastic or viscoelastic material being made according to the method defined in any one of claims 1 to 5.

8. Method according to claim 1, characterized in that the additive is selected from: a wax or wax-like compounds and mixtures thereof; a supersaturated crystalline solid / liquid; a liquid crystallizing compound; a non-Newtonian compound that solidifies; granules / powders / other solids that can flow into the elastic or viscoelastic material; liquids that can be hardened or can be arranged and oriented to be more rigid by other means.

9. Method, according to claim 1, characterized in that the plurality of interstices is a network of voids. Petition 870240107089, dated 12 / 16 / 2024, pp. 21 / 25

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